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XRF & XRD Laboratory
Automation for the Cement
Industry
Automatización de FRX y DRX
en laboratorios analíticos para la
industria de cementos
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• Introduction to IMP • The Case for Automation • Cement Laboratory Automation Concepts • Container Laboratory • On/In Line XRD & Process Control Instruments • Sample Collection and Transport • Sample Preparation
– Crushing – Milling – Pressing – Fusion – Laboratory Control
• Conclusion
Index
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IMP Group
IMP started in South Africa 25years ago
IMP is now 100% Australian owned – offices in Perth, Toronto, Belo Horizonte and Johannesburg
Work closely with Herzog to distribute, support and design sample prep equipment used for XRD, XRF, ICP etc
• Service and technical sales staff in each of these countries. Herzog and IMP employ more than 400 people
Globally we have sold more than 400 robots for sample prep
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IMP Group
IMP challenges the status quo of traditional sampling and sample processing.
We work with like-minded customers to provide innovative solutions from sampling to analysis that -
• Improve ergonomics, health and safety for laboratory operators,
• improve sample integrity, quality and precision of analytical data
• Increase productivity.
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• Iron and Steel
Cement
• Non-Ferrous • Mining
Key Industries
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Milestones
• Have supplied over 75 automated laboratories – The largest laboratory
automation project in the world to Anglo Platinum in South Africa (the facility is the size of a football pitch and uses 14 robots)
– The largest robotic sample preparation and wet chemistry system in the world for FMI (previously Phelps Dodge) in the USA
– The largest fully automated iron ore laboratory in the world for BHP BIO in Western Australia
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Traditional Sample Prep It’s horrible work
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Manual Handling
• In the manual based laboratory each sample could be handled up to six times in its full sample mass before being processed. Typically the process below was followed
• Sample pick up • Sample drop off • Sample riffled • Sample crushed • Sample loaded onto oven trolley • Sample removed from oven trolley • Sample pulverised • Sample weighed out for analysis
For every movement the risk of incurring a manual handling injury increased. There was also the risk around highly repetitive tasks
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Slide 9
NJV Manual x Automated Preparation
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Results
The Laboratory
Reliable, Accurate, Repeatable, Timely and Efficiently Produced
Getting Results
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Why Automate?
Automation Improves repeatability of results and precision Less chances for error
Less repeated samples More reliable results Less sample “mix-ups”
Provides a safer, cleaner and healthier work environment for employees More interesting work for employees Less insurance claims
Usually lower price per sample (cheaper) Programmed and managed maintenance schedules Higher productivity
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Laboratory Automation Concepts
Robotized Automation Concept
Linear Automation Concept
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Automated Cement Installations
• IMP’s partner, Herzog Japan, has installed 30+ automated cement labs.
• Thailand, the Philippines and Europe all have may automated Herzog/IMP labs
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Taiheito Cement - Raw Meal
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Cement - Linear System
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Cement Container Lab
System comprises: • Container to hold the
system • Automatic sampling
station (outside of lab) • Sample preparation • XRD, XRF and/or particle
Sizing Instrument & software communicates directly with plant control systems
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XRF/XRD Container Lab
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XRF/XRD Container Lab
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XRD Container Lab
Buzzi – SelmaPlant (USA)
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• Automatic mineral phase
analysis
• In plant On-Stream location
(in a container)
• Automated laboratory
• Linked to plant control system
• Continuous or Batch analysis
XRD
• Data trending
XRD for Process Control
IMP can automate most brands of XRD
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On/In-line XRD
XRD WILL DIRECTLY ANALYSE • CLINKER
– C3S, C2S, C3A, C4AF, CaO, and their various forms
– Other crystalline minerals if required
• CEMENT
– C3S, C2S, C3A, C4AF, CaO, Ca(OH)2, CaCO3, CaSO4.2H2O, CaSO4.1/2H2O, other crystalline minerals if required
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Mill exit cement after a power trip, July 28,2004
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SO3
Portlandite
Gypsum
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Lime
Alite-tricl
Alite-monoc
XRD Final Cement Composition
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Typical Results
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NITA Online Process Control
Elemental Analysis
NITA – Elemental Analyser. Designed by the Australian CSIRO. Long life Source (432 years), multiple detectors, never re-calibrate or replace the source = low running costs!!
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Results Achieved for Cement CaO (NITA)
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Cement Lab Automation
Sample Collection
Transport Sample
preparation Transport Analysis
• Cement • Clinker • Raw
material
• Crush • Split • Pulverise • Press and/or fuse • Fusion • Digestion / Wet Chemistry
• XRF • XRD • ICP-MS • Etc
Primary crush if Clinker and from mine
SAMPLE is TRACKED and MANAGED in PrepMaster and/or LIMS
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Delivery & Sampling
A range of sampling and sample delivery solutions for Clinker, Cement and raw meal. All
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Sample Preparation
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Manual Mills – with PLC
Semi Automatic Automatic
Sample Prep. - Mills
Mills
Bench top Mill
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Sample Prep. – Pressing
Manual & Semi Auto
IMP has a range of Manual and Semi Automatic Presses available. The HTP-40 Press (right) is an industry favourite
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Sample Prep.
Automatic Pressing
Automatic Mill and XRD Press Automatic Mill and Press
combined
HR-LA, Mill & Press with XRF
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Fusion - Auto Flux Weighing
New Free Flowing Flux
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Fusion – Semi to Fully Automatic
IMP has a range of Fusion instruments and accessories to suit your requirements, from manual to fully automatic
high output instruments
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Laboratory Control
Herzog Prepmaster software will control you Automated Laboratory
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• IMP has the expertise, experience and product to design, build and support your cement laboratory
• IMP can provide a complete solution – Online elemental analysis
– Automated Mineralogical Analysis (XRD)
– Automated Sample collection
– Automated Sample Sending
– Automated and/or manual sample preparation solutions
Conclusion